Collapsible transport container and retention mechanism for use therewith

ABSTRACT

Embodiments of the invention are directed to collapsible transport containers with hinged and/or removable side walls to facilitate container collapse, as well as latching mechanisms capable of securing the side walls of such containers to one another and releasing said side walls from one another without the need for tools. Embodiments of the invention are also directed to keeper assemblies that allow said latching mechanisms to guard against inadvertent unlatching and possible unintentional collapse of one or more container side walls.

TECHNICAL FIELD

The present invention is directed to returnable-type article shipping/transport container that can be at least partially collapsed when not loaded, and to a related retention mechanism for providing releasable engagement between side walls of such a container.

BACKGROUND

Article transport containers of various types and designs would be well known to those skilled in the art. While article transport containers may be disposable, the invention is primarily directed to article containers that may be returned and reused. Such article transport containers typically include a base and side walls that extend upward from the base to form an enclosed or at least partially enclosed structure. Such containers frequently include an open top, but may also be provided with a removable or otherwise openable top wall.

Individual shelves, compartments, hangers or other structures may be located within such an article transport container for the purpose of receiving and retaining articles. These containers are generally employed to store articles during transport from one location to another, such as from a source of the articles to an end user of the articles. Upon receipt at the end user location, the articles may be unloaded for later use—such as into other containers, carts, etc., that may be employed to transport the articles to a use location. Alternatively, articles may remain in a transport container for removal at the time of use, in which case the transport container itself may be placed at the location of use. In any case, once depleted of articles, transport containers of interest to the invention are intended to be reused by refilling with additional articles of a like or different kind. This process may involve returning the transport container to a source of articles to another location for refilling.

In a manufacturing setting, returnable or reusable containers may be used to facilitate the flow of parts for the manufacturing process. In this case, the containers may be employed to transport parts from a supplier facility to a manufacturing facility. Once a full container that has been received from the supplier is unloaded, it may be transported to a designated area at or near the manufacturing facility and prepared for shipment back to the supplier. The supplier then reloads the container with parts and the full container is transported back to the manufacturing facility.

It can be easily understood that transporting large transport containers or a large number of transport containers by truck, boat or other shipping means can require a substantial amount of space. While the space required to hold a loaded transport container may be fixed based on the storage volume of the erected transport container itself, the ability to reduce the volume occupied by an unloaded transport container is obviously of interest in order to maximize the number of such containers that can be carried within a given space. Consequently, foldable or otherwise collapsible transport containers have been developed, wherein it is possible to reduce the size of the transport container when unloaded. Most commonly, such transport containers include the ability to remove or otherwise fold down the normally upright side walls of the transport container in some fashion.

In the types of environments where transport containers are frequently used (e.g., manufacturing facilities), the time required to perform most any task is important. Consequently, while the ability to collapse a transport container is valuable from the standpoint of logistics and shipping costs, the value is diminished if excessive time is required to perform a container collapsing operation.

The required collapsing time has been problematic with respect to known collapsible transport containers. For example, known collapsible transport containers have employed fastener assemblies, such as bolts and nuts, to releasably affix the walls of such a container to one another. As such, an operator is required to carry the appropriate fastener actuation tool (e.g., wrenches), and to physically disassemble a plurality of individual fastener assemblies prior to actually collapsing the walls of the container. This process must be reversed when the container is later re-erected for subsequent reuse. The loss of such fastener assemblies is also a common problem.

Collapsible containers with side wall securing mechanisms that may be operated without the use of tools are also known. However, these known mechanisms have not adequately guarded against unintentional unlatching and the potential unintended collapse of one or more container side walls. Such an unintentional unlatching of these known side wall securing mechanisms can obviously result in damage to articles residing in the container and/or to injury of persons working with the container.

Therefore, there is a need for a returnable collapsible transport container that includes a latching mechanism capable of securing the side walls of the container to one another when the container is in an erected state, while also permitting the container to be easily and quickly collapsed without the need for tools. The latching mechanism should also guard against inadvertent unlatching and possible unintentional collapse of one or more container side walls.

SUMMARY

Collapsible transport container embodiments of the invention generally include a base to which a number of upright side walls are removably and/or hingedly, attached. The bases and side walls of collapsible transport containers of the invention may be constructed of various materials, may be of various sizes and shapes, and the number of side walls may vary. In any case, the side walls of a collapsible transport container of the invention will typically be adapted to be laid upon or to fold in on or over the base, such that the container may be substantially collapsed for transport when empty.

When in an erected state (i.e., when the side walls are placed in their upright positions), the side walls of a collapsible transport container of the invention must be secured to one another to provide the necessary rigidity to the container and to prevent the inadvertent collapse of one or more of the side walls. To this end, collapsible transport container embodiments of the invention also include latch mechanisms that may be operated without tools to secure adjacent sidewalls to one another.

In an exemplary embodiment, such a latch mechanism includes a latch rod that is slidably retained on a mounting plate or similar structure. The latch rod includes a handle portion for facilitating operation of the latch mechanism, and a latching portion having a bent distal end that is adapted to enter and engage a retention slot or notch. A keeper assembly is also provided, preferably in the form of cooperating retention elements between which a segment of the latch rod resides and is releasably retained when in a stored latched and/or stored unlatched orientation. In one exemplary embodiment, the latch rod is mounted on one side wall and an adjacent side wall includes the retention slot or notch into which the bent end of the latch rod latching portion is inserted to secure the side walls to one another.

To secure the aforementioned side walls to one another, a user generally grasps the handle portion of the latch rod that is mounted to one of the side walls and rotates the latch rod such that the handle portion is released from the keeper assembly and the bent end of the latch rod latching portion becomes properly oriented for insertion into the retention slot located on/in the other side wall. With the latch rod so positioned, the user then slides the latch rod toward the retention slot until the bent end of the latch rod is located therein. A stopper may be provided, such as on the latch rod, to halt sliding of the latch rod when this position has been reached. The user then rotates the latch rod handle back toward its initial orientation, such that the bent end of the latch rod latching portion rotates within the slot to prevent an unlatching movement of the latch rod, and the handle portion of the latch rod is once again releasably retained by the keeper assembly.

The keeper assembly functions to prevent an unintended rotation and possible inadvertent sliding movement of the latch rod. To this end, a keeper assembly of the invention includes cooperating retention elements that retain the latch rod in a stored (i.e., latched or unlatched) orientation wherein the latch rod cannot be slidably displaced. Retention of the latch rod by the keeper assembly results from engagement of a segment of the latch rod handle portion by cooperating retention elements of the keeper assembly. As a result of the keeper assembly, a desired orientation and position of the latch rod can be maintained unless the latch rod is deliberately released from the keeper assembly by a user or by some automated device adapted for that purpose.

BRIEF DESCRIPTION OF THE DRAWINGS

In addition to the features mentioned above, other aspects of the present invention will be readily apparent from the following descriptions of the drawings and exemplary embodiments, wherein like reference numerals across the several views refer to identical or equivalent features, and wherein:

FIGS. 1 a-1 c are perspective, side and end views, respectively, of one exemplary embodiment of a collapsible transport container of the invention in an erected state;

FIG. 2 is a perspective view depicting the container of FIGS. 1 a-1 c in a collapsed state;

FIG. 3 a is an enlarged view of one exemplary embodiment of a latch rod carrying portion of a latching mechanism of the invention, wherein associated latching mechanism elements including a keeper assembly are also visible;

FIG. 3 b is an enlarged view of one exemplary embodiment of a retention slot portion of a latching mechanism of the invention; and

FIGS. 4 a-4 c are perspective, top and side views, respectively, of one exemplary embodiment of a keeper assembly retention element of the invention.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENT(S)

One exemplary embodiment of a collapsible transport container 5 (hereinafter “container” for brevity) of the invention is illustrated in an erected state in FIGS. 1 a-1 c. As shown, this exemplary container 5 includes a base 10 and four side walls 15-30. The side walls are shown in FIGS. 1 b and 1 c removed from the base for clarity.

In this exemplary embodiment of the container 5, the base 10 and side walls are constructed from a metallic material, such as steel, and are assembled by welding. In other embodiments, different materials may be employed for the base and/or side walls. For example, the base and/or one or more side walls of other embodiments of a container of the invention may be comprised of plastic, fiberglass, composites, etc., and may be molded or otherwise formed. As described above, it is also possible for the base and/or walls of a container of the invention to be of a shape that is different than the shape shown in FIGS. 1 a-1 c, to be of various different sizes, and to include some numbers of side walls other than the four side walls shown.

In this exemplary embodiment of the container 5, the side walls 15-30 are both removable from and hinged to the base 10 when associated therewith. In other embodiments, the side walls of a given container may be only removable or only hinged, such that they may be stacked upon or folded over the base, as the case may be, to permit the container to be collapsed when empty. The container 5 of FIGS. 1 a-1 c is shown in a collapsed state in FIG. 2.

As can be seen in FIGS. 1 a-1 c, and more clearly in FIGS. 3 a-3 b, the container 5 includes several latch mechanisms 35 that function to secure the side walls 15-30 to one another when the side walls are raised and the container is in an erected state as represented in FIGS. 1 a-1 c. In this embodiment, one portion of each latch mechanism is associated with a first side wall and another portion of the same latch mechanism is associated with an adjacent side wall to which the first side wall will be secured. For example, as shown in FIGS. 1 b and 1 c, the side wall identified as 30 includes one (latch rod-carrying) portion of the latch mechanism 35 and the adjacent side wall identified as 25 includes a corresponding (retention slot containing) portion of the latch mechanism 35, such that the side walls 25, 30 may be secured to one another when in an upright orientation on the base 10. Such a latch mechanism 35 is located at each corner of the container 5, such that the side walls 15-30 may be securely but releasably interlocked with one another so as to produce a sufficiently strong and rigid container 5.

A more detailed view of the latching mechanism 35 is available in FIGS. 3 a-3 b. Referring to FIG. 3 a, it can be observed that the latch mechanism 35 includes a number of elements that are secured to a mounting plate 40 which is, itself, attached to a side wall (e.g., side wall 30) of the container 5. The mounting plate 40 may include bent ends that extend substantially transversely to the remainder of the mounting plate to form spaced latch rod guiding and retention plates 45A, 45B. Alternatively, separate plates or other suitable structures or devices (e.g., bushings, bearings, etc.) may be attached to the mounting plate 40 for this purpose. The plates 45A, 45B include respective holes 50, 55, through which portions of a latch rod 60 of the latch mechanism 35 pass.

In this exemplary embodiment of the latch mechanism 35, the latch rod 60 is comprised of metallic rod stock and, therefore, has a substantially circular cross-section. The material of which the latch rod is comprised and the cross-sectional shape thereof may be different in other embodiments, so long as acceptable rotation of the latch rod may be accomplished.

The latch rod 60 includes a latching portion 65 that passes through the holes 50, 55 in the latch rod guiding and retention plates 45A, 45B. An area near the first, proximal end 65A of the latch rod latching portion 65 may be formed, deformed, or provided with a stop 90 to prevent said first end of the latch rod from passing through the hole 50 in the associated plate 45A when the latch rod is slidably operated as described below. A second, distal end 65B of the latch rod latching portion 65 is bent so as to facilitate its entrance into and engagement with a retention slot or notch 105, as also described below. The stop 90 and the bent distal end 65B of the latch rod latching portion 65, in combination with the guiding and retention plates 45A, 45B, are operative to slidably retain the latch rod 60 on the mounting plate 40. Bushings or other suitable devices may be inserted into the holes 50, 55 to facilitate sliding of the latch rod 60 therein.

The latch rod 60 is also shown to include a handle portion 70 that is provided to facilitate operation of the latch mechanism 35, and also to releasably lock the latch rod in a stored (i.e., latched or unlatched) orientation, as will be explained below. In this exemplary embodiment, the handle portion 70 is substantially U-shaped, with two legs 70A, 70B that extend substantially transversely from the latch rod latching portion 65 and a third leg 70C that connects the transverse legs. Other handle shapes are possible in other latch mechanism embodiments.

In the embodiment shown, the handle portion 70 extends vertically downward from the latch rod latching portion 65 when the latch rod 60 is in a stored orientation, but it should be realized that in other latch mechanism embodiments, the handle portion may be located to extend in a different manner when the latch rod is in a stored orientation. For example, the latch mechanism of another embodiment may be of a design that substantially mirrors the arrangement shown in FIG. 3 a.

Referring now to FIG. 3 b, it can be seen that the latch mechanism 35 also includes a retention slot 105 located in a corresponding face 15A of an adjacent side wall 15. The slot 105 is shaped to cooperate with the latch rod 60 such that the bent distal end 65B thereof may enter the slot when the latch rod is sufficiently rotated away from a stored orientation, but will be trapped in the slot when the latch rod is rotated back to the stored orientation. The slot 105 may reside in only one face 15A of its associated side wall 15 or it may pass fully therethrough, in which case the bent end 65B of the latch rod 60 may also extend fully through the side wall when engaged with the slot.

A reinforcing plate 110, which includes a like retention slot 105, may be attached to the slot-containing side wall 15 to strengthen the side wall engagement area. In another embodiment (not shown), a retention slot may be formed in a separate plate or structure that is then attached to a given side wall such that the retention slot is not located in the side wall itself. In any case, engagement of the bent end 65B of the latch rod 60 with the retention slot 105 is operative to securely but releasably couple the adjacent side walls 15, 30.

Referring back to FIG. 3 a, it can be observed that the latch mechanism 35 is also provided with a keeper assembly 75 to maintain the latch rod 60 in a stored orientation, as described above, when the latch rod is in a latched or unlatched state. That is, the keeper assembly 75 functions to prevent an unintended rotation and possible inadvertent sliding movement of the latch rod 60.

This embodiment of the keeper assembly 75 includes cooperating retention elements between which a segment of the latch rod handle 70 resides and is releasably retained when in a latched or unlatched state. More particularly, this exemplary embodiment of the keeper assembly 75 includes a pair of spaced apart retention tabs 80A, 80B that project outwardly from the mounting plate 40 toward the latch rod 60.

Disposed between the retention tabs 80A, 80B of the keeper assembly 75 is a cooperating latch rod retention element 85. In this particular example, the keeper assembly 75 is designed and located to releasably engage the transverse legs 70A, 70B of the latch rod handle 70. Since the transverse legs 70A, 70B of the latch rod handle 70 are of the same cross-sectional size and shape in this example, the latch rod retention element 85 is located substantially equidistantly between the retention tabs 80A, 80B. Similarly, the spacing between the latch rod retention element 85 and each retention tab 80A, 80B is sufficiently large to permit the transverse legs 70A, 70B of the latch rod handle 70 to be forcibly inserted between and removed from between the latch rod retention element and the corresponding retention tab, while also being sufficiently tight to retain the latch rod handle against non-deliberate removal.

As can be observed in FIG. 3 a and, more so in FIGS. 4 a-4 c, at least the latch rod retention element 85 may be designed and/or constructed to aid in the releasable retention of a portion (handle, in this example) of the latch rod 60. For example, the latch rod retention element 85 may be provided with a shape that resistively permits passage of the latch rod handle legs 70A, 70B, such that the handle may be rotated into or away from a stored orientation only upon exertion of a deliberate rotational force (i.e., a force of a magnitude not likely to be produced by inadvertent contact between the handle and another object, etc.).

In this particular embodiment, the latch rod retention element 85 is somewhat bulb-shaped for the purpose of providing resistive handle passage. More particularly, the latch rod retention element 85 is generally cylindrical, but its diameter along a proximal base portion 90 (i.e., closer to the mounting plate 40) is less than the diameter of its distal portion 95. Consequently, the distal portion 95 of larger diameter forms a projecting annular lobe 100 that acts to resist, but not prevent, passage of the transverse latch rod handle legs 70A, 70B by producing a reduced gap of small surface area between the latch rod retention element 85 and the associated retention tabs 80A, 80B. The use of other shapes for the same purpose is also possible in other embodiments.

The latch rod retention element 85 and, optionally, the retention tabs 80A, 80B may also be comprised of a material that facilitates resistive passage of the latch rod handle legs 70A, 70B therebetween. For example, in this exemplary embodiment, the latch rod retention element 85 is manufactured from a material, such as without limitation nylon, that is sufficiently hard while also being slightly deformable [is this true?] and exhibiting a low coefficient of friction. The use of such a material further facilitates the resistive passage of the latch rod handle legs 70A, 70B past the annular lobe 100 of the latch rod retention element 85 when a deliberate rotational force is applied to the handle, while still allowing the keeper assembly 75 to perform the function of otherwise retaining the latch rod 60 in a stored orientation when latched or unlatched.

In other embodiments of a latch mechanism and associated keeper assembly, the keeper assembly retention elements may engage with other parts of the latch rod and, therefore, the arrangement of the retention elements shown in FIG. 3 a may be different. Additionally, in some embodiments it may be desired that the latch rod of a latch mechanism be retained in a stored orientation only when the latch mechanism is latched (as shown in FIG. 3 a). Consequently, other keeper assembly embodiments may include fewer retention elements than the embodiment shown in FIG. 3 a.

Operation of the latch mechanism 35 will now be explained in the context of its use to secure the side walls 15, 30 of the container 5 of FIGS. 1 a-1 c to one another. This description of exemplary latch mechanism operation assumes that the latch mechanism is initially in a stored and unlatched orientation/position. It should be apparent that the other latch mechanisms 35 present on the container 5 would be similarly operated as described below to secure side wall 15 to side wall 20, and side wall 25 to side wall 20 and side wall 30.

With the side walls 15, 30 in their upright (erected) positions, a user generally grasps the handle portion 70 of the latch rod 60 and rotates the latch rod such that the transverse leg 70B of the handle portion is released from engagement with the latch rod retention element 85 and cooperating retention tab 80A of the keeper assembly 75. The latch rod 60 is rotated by an amount (e.g., 90°) that also causes the bent distal end 65B of the latch rod latching portion 65 to rotate into proper orientation for insertion into the retention slot 105 located on/in the side wall 15.

With the latch rod 60 so positioned, the user then slides the latch rod toward the adjacent side wall 15 (toward the right, as shown in FIG. 3 a) until the bent end 65B of the latch rod is located in the retention slot 105. The stopper 90 on the latch rod 60 may be located to halt the sliding movement of the latch rod when this position has been reached. The user then rotates the latch rod 60 back toward its initial orientation, such that the bent end 65B of the latch rod latching portion 65 rotates within the retention slot 105 to prevent a subsequent sliding (unlatching) movement of the latch rod, and the handle portion 70 of the latch rod is once again releasably retained in a stored orientation by the keeper assembly 75. As the latch mechanism is now in a latched position, the latch rod handle leg 70B is now releasably retained by cooperation of the latch rod retention element 85 and the retention tab 80B of the keeper assembly 75. The side walls 15, 30 are thereby releasably secured to one another without the need for tools, and the latch rod is releasably retained in a stored and latched position such that an unintended unlatching of the side walls is avoided.

While certain exemplary embodiments of the present invention are described in detail above, the scope of the invention is not to be considered limited by such disclosure, and modifications are possible without departing from the spirit of the invention as evidenced by the following claims: 

What is claimed is:
 1. A collapsible transport container, comprising: a base; a plurality of side walls removably and/or hingedly connected to the base such that the side walls substantially enclose the perimeter of the base when in an erected orientation; a side wall retention mechanism located at each corner of the container, a first portion of each retention mechanism located on one side wall and a cooperating second portion of each retention mechanism located on an adjacent side wall, the retention mechanisms operable to releasably secure the side walls of the container to one another; and a keeper assembly associated with each retention mechanism, each keeper assembly adapted to engage a latch element of a respective retention mechanism so as to inhibit inadvertent unlatching thereof.
 2. The collapsible transport container of claim 1, wherein the side walls are removable from the base and may be removed and laid one on top of the other on the base when the container is collapsed.
 3. The collapsible transport container of claim 1, wherein the side walls are hinged to the base and may be rotated inward to lie on the base when the container is collapsed.
 4. The collapsible transport container of claim 1, wherein the first portion of each side wall retention mechanism is a latch-carrying portion and the cooperating second portion of each side wall retention mechanism is a retention slot.
 5. The collapsible transport container of claim 5, wherein there are four side walls, the latch carrying portions of the side wall retention mechanisms are disposed in spaced pairs on opposite ends of one side of two opposed walls, and the retention slot portions of the side wall retention mechanisms occur at opposite ends of the remaining two side walls.
 6. The collapsible transport container of claim 1, wherein the retention mechanism includes a mounting plate that is attached to a side wall of the container and carries the elements of the first portion of the retention mechanism, and wherein the second portion of the retention mechanism comprises a retention slot in an adjacent side wall.
 7. The collapsible transport container of claim 6, wherein the first portion of the retention mechanism includes a latch rod that is slidably displaceable along the mounting plate to engage the retention slot in the adjacent side wall.
 8. The collapsible transport container of claim 7, wherein the latch rod includes a latching portion having a bent distal end for engaging the retention slot and a handle portion for facilitating operation of the latch rod.
 9. The collapsible transport container of claim 8, wherein the retention slot is shaped such that the bent distal end of the latch rod may pass therethrough when the latch rod is rotated away from a stored orientation but cannot pass therethrough when the latch rod resides in a stored orientation.
 10. The collapsible transport container of claim 7, further comprising a keeper assembly associated with the mounting plate and adapted to releasably engage a portion of the latch rod when the latch rod is in a stored latched or unlatched orientation.
 11. The collapsible transport container of claim 10, wherein the keeper assembly includes at least one projecting retention tab and an associated latch rod retention element disposed at some distance therefrom.
 12. The collapsible transport container of claim 11, wherein the at least one projecting retention tab and the associated latch rod retention element of the keeper assembly cooperate to releasably retain a portion of the latch rod when the latch rod is in a stored orientation.
 13. The collapsible transport container of claim 12, wherein the portion of the latch rod that will be releasably retained by the keeper assembly is a leg of the latch rod handle.
 14. A retention mechanism for use with a collapsible transport container, comprising: a mounting plate for attachment to a side wall of the container; a latch rod slidably retained on the mounting plate, the latch rod including a latching portion having a bent distal end and a handle portion for facilitating operation of the latch rod; a retention slot located in a side wall that is adjacent to the side wall to which the mounting plate will be attached, the retention slot shaped such that the bent distal end of the latch rod may pass therethrough when the latch rod is rotated away from a stored orientation but cannot pass therethrough when the latch rod resides in a stored orientation; a keeper assembly associated with the mounting plate, the keeper assembly including at least one projecting retention tab and an associated latch rod retention element disposed at some distance therefrom, the at least one projecting retention tab and associated latch rod retention cooperative to engage and releasably retain a portion of the latch rod when the latch rod is in a stored latched or unlatched orientation.
 15. The retention mechanism of claim 14, wherein the latch rod retention element of the keeper assembly is shaped so as to provide a limited area of reduced gap with the cooperating retention tab and a limited area of increased resistance to passage of the affected portion of the latch rod.
 16. The retention mechanism of claim 14, wherein the latch rod retention element of the keeper assembly is comprised of a material having a low coefficient of friction.
 17. The retention mechanism of claim 14, wherein there are two projecting retention tabs and the latch rod retention element is located substantially equidistantly therebetween to releasably retain the latch rod in either a stored latched or stored unlatched orientation.
 18. The retention mechanism of claim 14, wherein the portion of the latch rod that is releasably retained by the keeper assembly is a leg of the latch rod handle.
 19. A keeper assembly for use with a collapsible transport container retention mechanism having a slidable latch rod, the keeper assembly comprising: a mounting plate for attachment to a side wall of the container; a pair of retention tabs projecting outwardly from the mounting plate; a latch rod retention element extending outwardly from the mounting plate and disposed substantially equidistantly therebetween, the latch rod retention element being shaped so as to provide a limited area of reduced gap with the retention tabs and a resulting limited area of increased resistance to passage of an affected portion of a retention mechanism latch rod, such that the retention tabs and associated latch rod retention element are cooperative to engage and releasably retain the affected portion of the latch rod when the latch rod is in a stored latched or unlatched orientation.
 20. The keeper assembly of claim 19, wherein the latch rod retention element of the keeper assembly is comprised of a material having a low coefficient of friction. 